Ceramic Atomization Core Structure for Powder-Fall and Heavy Metal Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The atomization core of electronic cigarettes is prone to powder-falling due to thermal cycling and E-liquid erosion, and heavy metal substances can be entrained into the airflow, posing health hazards.
Innovation Solution
An atomization core with a porous ceramic substrate and a ceramic covering layer of lower porosity, combined with a heating film, where the ceramic covering layer prevents direct contact with the heating component and isolates heavy metal precipitates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a porous ceramic substrate is used in the atomization core, then liquid guidance and distribution are improved, but powder-falling occurs due to thermal cycling and E-liquid erosion
Solution Approach 1:
The patent applies composite materials by combining a porous ceramic substrate with a ceramic covering layer having different porosity characteristics. The porous substrate (40-80% porosity) provides liquid guidance while the covering layer (10-20% porosity) prevents powder-falling, creating a composite structure that resolves the contradiction between liquid distribution and structural stability.
Solution Approach 2:
The patent implements local quality by creating a gradient porosity structure where the inner porous substrate has high porosity (40-80%) for liquid absorption and guidance, while the outer covering layer has low porosity (10-20%) for mechanical strength and powder retention. This spatial variation in porosity resolves the contradiction between liquid guidance and powder-falling resistance.
2Power
If heavy metal substances are present in the atomization core, then heating function is achieved, but heavy metal entrainment into airflow causes health hazards
Solution Approach 1:
The patent uses the ceramic covering layer as an intermediary barrier between the heating elements (containing heavy metals) and the airflow. This intermediate layer prevents direct contact and entrainment of heavy metal particles into the vapor stream, eliminating health hazards while preserving the heating function.
Solution Approach 2:
The patent converts the potential harm of heavy metal presence by using the ceramic covering layer to contain heavy metal particles within the atomization core structure. The covering layer transforms the harmful effect into a beneficial containment mechanism, preventing particle release while maintaining heating efficiency.
3Quantity of substance
If the ceramic covering layer has high porosity to match the substrate, then liquid permeability is improved, but powder-falling risk increases
Solution Approach 1:
The patent applies parameter changes by deliberately setting the porosity of the ceramic covering layer (10-20%) to be lower than that of the porous substrate (40-80%). This parameter differentiation creates an optimal balance where the covering layer maintains sufficient liquid permeability while providing the structural stability needed to prevent powder-falling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Prevents powder-falling and heavy metal entrainment, enhancing the safety and performance of the electronic atomization device by ensuring uniform liquid guidance and reducing health risks.
Implementation Method 1
a porous ceramic substrate, a ceramic covering layer, and a heating film. The ceramic covering layer is combined on a surface of the porous ceramic substrate
Implementation Method 2
a heating film. The ceramic covering layer is combined on a surface of the porous ceramic substrate, the heating film is combined on a surface of the ceramic covering layer away from the porous ceramic substrate
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
An electronic atomization device, an atomization core (100) and a preparation method therefor. The atomization core(100) comprises a porous ceramic base material (10), a ceramic covering layer (20) and a heating film (30) wherein the ceramic covering layer (20) is combined with the surface of the porous ceramic base material (10), the heating film (30) is combined with the surface, away from the porous ceramic base material (10), of the ceramic covering layer (20), the porosity of the ceramic covering layer (20) is lower than that of the porous ceramic base material (10), and a plurality of through holes (21) are formed in the ceramic covering layer (20). The ceramic covering layer (20) with a porosity lower than that of the porous ceramic base material (10) is combined with the surface, close to the heating element, of the porous ceramic base material (10), and the ceramic covering layer (20) with a lower porosity is higher in density and free of the powder falling phenomenon, such that the powder falling phenomenon of the atomization core (100) can be prevented, and furthermore, the ceramic covering layer (20) with a lower porosity can isolate precipitates of heavy metal in the porous ceramic base material (10), such that heavy metal can be prevented from being brought into airflow during suction, thereby improving the safety performance of the electronic atomization device.